Presented in AUPEC 2007, Perth, Western Australia, 9-12 December, 2007

Limitations of Using Single Medium Voltage Station Auxiliary Supply System in Large Thermal Power Plants--Some Possible Solutions
Dr. Noor M Shiekh Dean of Electrical Engineering University of Engineering & Technology, Lahore, Pakistan Email: deanee@uet.edu.pk Mohammad Amon Khan Chief Engineer National Engineering Services Pakistan Ltd. (NESPAK) Lahore, Pakistan Email: nateng@lhr.paknet.com.pk

Abstract
Past experience with large thermal power units (>650 MW) had led to a tentative conclusion that a single medium voltage auxiliary supply system at 6.9kV voltage level can satisfy the power plants reliability and operational flexibility design criteria[1]. However, recent experience in the use of single medium voltage system reveals several inherent limitations that require careful assessment of plant auxiliary loads and system configurations when selecting a particular auxiliary system voltage level and equipment. Specific switchgear ratings, depending upon their application to a particular auxiliary supply system configuration, may put constraints on short circuit and voltage regulation which become mutually exclusive with the introduction of larger units characterized by increased unit auxiliary loads. The medium voltage switchgear ratings also limit the loadings on the switchgear buses and impose a practical limit on the size/capacity utilization of transformer that supplies the unit/power plant auxiliary loads. These load restrictions have become more pronounced with increase in the size of thermal power units. This paper attempts to highlight the inherent limitations of using single medium voltage system. Studies conducted for this purpose give rise to several important design considerations. Several innovative engineering solutions considered in this paper will help design engineers understand more clearly the pros and cons of medium voltage system issues specific to their projects.

1. Basic Design Issues

The two major limitations worth considering in the design of station auxiliary supply systems are the voltage regulation and system capacity constraints that have acquired greater significance because of the increased unit auxiliary loads of large thermal power plants. The ratings of the electrical equipment are established based on system short circuit and the voltage regulation studies, which must be carried out for every Project. The short circuit studies are performed to ensure that the fault contributions from the electrical source and the motors connected to the plant buses do not exceed the selected switchgear short circuit ratings. Conversely switchgear can be selected to suit the calculated short circuit currents. The equipment short circuit ratings are governed by international standards. The ANSI C37.06-1997 Standard for AC high voltage circuit breakers identifies only a single choice of 8.25kV class circuit breaker with a short circuit rating of 40 KA for use on 6.9kV system. This standard was revised to reflect the new ratings and to harmonize better with IEC Standards. [2] Lower transformer impedance provides better voltage regulation. However, lower impedance results in
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greater short circuit contribution from the transformer. Hence, the system regulation and short circuit capability present conflicting requirements. The transformer impedance can only be reduced up to a certain limit beyond which the switchgear short circuit ratings are violated. The short circuit studies are carried out normally with 1.05 PU pre-fault voltages at all the buses and with minimum system impedances (e.g. negative tolerances on transformer impedances). The voltage drop studies, on the other hand, utilize maximum equipment impedances and minimum grid voltage conditions. Although these assumptions are conservative, some short circuit margin between the calculated short circuit current and the equipments available short circuit interrupting capability must be applied to cater for addition of future motor loads, degradation of equipment due to aging, inaccuracies in the short circuit studies specially due to non-availability of firm load data, etc. Electrical Power Research Institute (EPRI) recommends a short circuit margin of 3 to 5 % over the switchgear manufacturers guaranteed short circuit ratings. [3] Load calculations establish the Ampere/MVA ratings of the electrical equipment. It must be ensured that the coincident loads are such that the temperature rise of the equipment is within limits established by Industry Standards. As with short circuit ratings, the ANSI
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standards identify standard continuous current ratings of 1200A, 2000A and 3000A for switchgear buses and breakers. The higher the motor load the higher will be the motor current contribution during a fault. It means that transformer contribution must be accordingly less for a given switchgear rating. This implies higher transformer impedance which worsens voltage regulation. Motor designs utilizing reduced starting currents are known to improve the voltage regulation. If acceleration time requirements are specified and the inertia and speed vs. torque characteristics of the driven load are known, a motor can be designed to develop the amount of torque required during acceleration to meet a desired time parameter. Specially designed motors use a wedge type rotor design in lieu of double cage deep bar rotor. [4] Another method of improving voltage regulation is to use Variable Frequency Drives (VFDs). The voltage regulation study must confirm that the system voltages will be adequate for steady state conditions as well as for transient conditions, such as during motor starts. The industry standards (e.g. ANSI C50.41-1982) define the acceptable voltage operating range of 10% of nominal rating under steady state conditions. For the transient voltage conditions, this standard allows voltages at motor terminals up to 85% of motor nameplate rating. However, as per IEEE Standard 666-1991, system designs that permit transient voltage dips of 20-25% are not uncommon in power plants. The primary consideration during these extreme motor-starting dips is the drop out voltage of relays and contactors rather than the effect on auxiliary equipment. The steady state load results in a voltage drop across transformer. The transformers fitted with on-load tap changers (OLTC) can compensate for utility system voltage variation up to the limit of the adjustable range of the OLTC. Once this limit is exceeded, the voltage drop across the transformer will again increase as a function of load. As the load is increased further, there will be a limit at which steady state voltage will be unacceptable. This load limit can be translated into the practical limit on transformer ratings i.e. a transformer with ratings above the maximum loading point is considered as oversized. The maximum loading on a transformer is also a function of power system/grid voltage. The lower the grid voltage, the lesser will be the allowable voltage drop across the transformer and lower will be the allowed load.

single medium voltage system at 6.9kV nominal voltage. The simplified configuration is shown in Figure 1.

A three winding main auxiliary transformer (MAT) is dedicated to supply auxiliary loads connected to the two unit switchgear buses for each generating unit. Each of the unit auxiliary switchgear buses has alternate feed from the two reserve auxiliary transformers (RAT) via station common RAT switchgear buses. Each of the two unit auxiliary buses feeds its related secondary unit substation (SUS) bus at 480V level via 6.9kV/480V SUS transformers. The SUS buses supply 480V motor loads directly and via Motor Control Centers (MCC). The two three winding RATs supply the station common loads in addition to unit auxiliary loads of the four units during start-up and shutdown.

3. System Design Criteria

The following reliability, operational flexibility and design criteria are used for the assumed Power Plant: 1. The AC power supply system shall be designed to provide all electrical requirements for units to operate under maximum expected conditions at 105% of normal throttle pressure. Failure of one start-up source (RAT) shall not prevent any unit from being started or shutdown. The supply to running loads of any two units shall be available when these trip simultaneously with transfer of their auxiliary loads on to the two RATs. Each RAT shall be sized at its OA rating to supply the loads of one starting unit, one running unit plus the entire station common service loads. The largest motor shall be capable of being started without allowing the bus voltage to drop below 90% of the bus rated voltage. The 6.9 kV motors shall be designed to be started at 80% of their nameplate rating. The motors shall have a 15% margin over driven equipment operating range maximum brake horsepower. The switchgear shall be ANSI Class 8.25 kV, 3000A with 40KA short circuit interrupting capability for use on a 6.9kV nominal voltage system.

2.

3.

2. MV System Configuration Thermal Power Plants

In

Large
4.

A large thermal power plant comprising 4 x 700 MW steam turbine-generator units is considered in this paper to elaborate the issues involved. The unit and station auxiliary power supply system assumed is a
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5.

The power plant auxiliary supply system shall be designed to provide satisfactory performance during emergency conditions for power system (grid) voltage as low as 90%.

5.1. Short Circuit Calculations

The short circuit calculations were performed for two system configurations to arrive at worst-case short circuit values. Pre-fault voltages of 1.05 PU at all the buses and minimum system impedances were considered for this purpose. The system configurations are:

4. Plant Loads
The equipment ratings assumed based on available load data from comparable size of units are shown in Table 1: Table 1: Plant Medium Voltage Auxiliary Loads Description
F.D. Fan Boiler Feed Pump Condensate Pump Gas Recirculation Fan CCCWP Circulating Water Pump Boiler Circulating Fan Aux. Circ. Water Pump Chlorination Rectifier Total

5.1.1. Configuration SA
The X-windings of RATs supply one running unit load (Unit 1), one starting unit load (Unit 2); the Y winding of RATs supply the common system loads. The auxiliary loads of Units 3 and 4 are fed from the respective unit MATs.

Load (kW)
5800 6050 1550 880 480 2150 590 690 4750 22940

5.1.2. Configuration SB
The Y-windings of RATs supply one running unit load (Unit 3), one starting unit load (Unit 4); the Xwindings of RATs supply the common system loads. The auxiliary loads of Units 1 & 2 are fed from related MATs. This case is studied because of difference in 6.9kV non-segregated bus involved between various buses for configuration SA and SB.

5. Short Circuit and Voltage Drop Studies

The short circuit and voltage drop studies were performed using Electrical Transient Analysis Program (ETAP) developed by Operation Technology Inc., California, USA. The key system data used in these studies are summarized in Table 2 below: Table 2: Key System Data Reserve Aux. Transformer Generator Transformer Main Aux. Transformer SUS Transformer Parameters Generator

5.1.3. Results of Short Circuit Calculations

The maximum short circuit currents on the worst-case 6.9kV common system bus, 6.9kV unit bus and 480V SUS bus obtained are summarized in Table 3. Table 3: Worst Case Short Circuit Currents Max. Interrupting Current KA Configuration Momentary Current KA
64.41 61.97 45.66 65.54 61.97 45.66
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Voltage Rating (KV)

23

400-23 23-2x6.9 864 14 @ 864 10 10 40

3802x6.9 50

6.90.480 2 8@2

MVA Rating 868.4 (MVA) Impedance (% @ MVA) Tolerance Imp. % Transformer Taps X/R Ratio (@ % Loss) X"d (Saturated) X'd (Saturated) in 0.233 0.271

23.5 @ 15 @ 40 50 7 5 10 +5 to -15

SA 7.5 5 SB

Common RAT 6.9kV Switchgear bus 56 B Unit 7, 6.9kV Switchgear Bus 1B 480V Unit 6 SUS 2A Common RAT 6.9kV Switchgear bus 78 B Unit 5, 6.9kV Switchgear Bus 1B 480V Unit 6 SUS 2A

6.9kV Bus

38.96 39.51 35.76 40.21 39.51 35.76

(OLTC) (No Load) (OLTC) (No Load)

50 (0.28) 31 (0.5) 47 (0.5) 5.4 (1.5) -

The above short circuit currents are within the 6.9kV switchgear maximum interrupting capability of 40KA.

The ultimate three phase fault level at the power plant 380kV bus was assumed as 38.1KA (symmetrical). The utility X/R ratio is assumed as 23.7. The cable impedances were based on typical data contained in ETAP Library. The load data used for these studies is depicted in Table 1.
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5.2. Voltage Drop Calculations

The voltage drop calculations were performed for various system configurations considering minimum grid (0.9PU) voltages and maximum equipment impedances. Only two system configurations will be discussed here.

Presented in AUPEC 2007, Perth, Western Australia, 9-12 December, 2007

5.2.1. Configuration VA
In this configuration, each unit load is fed from its MAT and the two RATs supply the common system loads. This is the normal operation configuration.

design to have either 6.9kV or 7.2kV nameplate ratings instead of standard 6.6kV. The results of the studies performed are shown in Table 5. Table 5: Voltage Drop with System Voltage 7.2kV Motor Terminal Configuration 7.2kV Bus 480V Bus

5.2.2. Configuration VB
In this configuration, the X-windings of RATs supply one running unit load (Unit 1), one starting unit load (Unit 2); the Y-windings of RATs supply the common system loads. The auxiliary loads of Units 3 & 4 are fed from related MATs.
VA

5.2.3. Results of Voltage Drop Calculations

The results of the voltage drop studies are summarized in Table 4. Table 4: Summary of Voltage Drops Motor Terminal Configuration 6.9kV Bus 480V Bus

Start of MDBFP Start of FD Fan Start of MDBFP VB Start of FD Fan

83.0 % 83.7 % 73.9 % 75.2 %

82.6 % 82.9 % 73.5 % 74.4 %

80.9 % 71.4 %

Notes

(a) 15% Margin on all Motors. (b) 650% FLC start current of all motors except FD Fan. (c) 610% FLC start current of FD Fan (d) ANSI 500MVA Class, max Switchgear rating 8.25kV, 40KA

VA

Start of MDBFP Start of FD Fan Start of MDBFP Start of FD Fan

79.2 % 80.1 % 68.4 % 70.2 %

81.8 % 82.4 % 70.7 % 72.1 %

77.9 % 68.0 % -

Motor Terminal

Configuration

(a) 15% Margin on all Motors. (b) 650% FLC start current of all motors except FD Fan. (c) 610% FLC start current of FD Fan (d) ANSI 500MVA Class, max Switchgear rating 8.25kV, 40KA

The above case shows improvement over the specified system (See Table 4) but fails to satisfy voltage regulation design criteria.

6.2. Limiting the starting currents of large motors

The effects of using reduced starting current motors on the voltage regulation are shown in Table 6. Table 6: motors The use of reduced starting current

VB

6.9kV Bus

Clearly, the above results indicate inadequacy of the specified system not only from the motor starting point of view but also due to the effect of the 6.9kV bus voltage drop at the lower voltage buses which may be a matter of concern for the MCC contactors dropping open. Based on the voltage drop studies performed, the 6.9kV system as per design criteria and project specification is judged not to have acceptable voltage regulation.

480V Bus

VA

Start of MDBFP Start of FD Fan Start of MDBFP Start of FD Fan

85.9 % 85.7 % 78.5 % 78.6 %

88.9 % 88.4 % 81.3 % 81.0 %

84.9 % 77.1 % -

Several design options were considered in an attempt to improve voltage regulation while retaining the specified 6.9kV single medium voltage system. A brief description and the results of the studies are given below:

The use of reduced starting current motor improves the voltage regulation. It is however certain that with the specified 15% motor margin, the voltage regulation is likely to worsen further.

6.1. Enhancing The Auxiliary Voltage From 6.9kv To 7.2kv.

This option would involve changing the transformer secondary voltage ratings and changing the motor
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VB

6. Options For Improvement of Voltage Regulation

(a) 5% Margin on all Motors. (b) 500% FLC start current of all motors ( FD Fan and MDBFP). (c) ANSI 500MVA Class, max Switchgear rating 8.25kV, 40KA

Notes
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6.3. Increasing the ratings of Switchgear to 48KA or 63KA

The results with 50 kA and 63KA switchgears are summarized in Tables 7 and 8, respectively. Table 7: Switchgear Configuration Voltage drop results with 50KA Motor Terminal

7. 6.9kv Switchgear Overloading -System Capacity Limitations

The specified 3000A, 6.9kV switchgear when de-rated for 50oC ambient temperature allows a maximum of 2700A load to be connected to any reserve auxiliary bus. This translates into a maximum RAT winding rating of 32.25MVA that can be fully utilized. The results of the loading studies performed for different possible operating scenarios are summarized in Table 9. Table 9: Reserve Auxiliary Bus Loading
RAT 1A X- Winding RAT 1A Y- Winding RAT 1B X- Winding 26.15 34.05 44.15 8.15 RAT 1B Y- Winding 16.2 16.2 16.2 54.7
196

6.9kV Bus

480V Bus

Notes

VA

Start of MDBFP Start of FD Fan Start of MDBFP Start of FD Fan

83.7 % 84.8 % 76.4 % 77.8 %

87.5 % 88.6 % 79.8 % 81.4 %

82.8 % 76.3 % -

(a) 15% Margin on all Motors. (b) 650% FLC start current of all motors except FD Fan. (c) 610% FLC start current of FD Fan (d) ANSI 1000MVA Class, max Switchgear rating 15kV, 50KA

The results of the analysis in Table 7 indicate that there is an improvement in voltage regulation over the comparable cases shown in Tables 4 to 6. Table 8: Switchgear Configuration Voltage drop results with 63KA Motor Terminal

1 Unit fast transfer to RAT- 2 RATs available. 1 Unit start-up with fast transfer of associated running Unit- 2 RATs available. 1 Unit running on RAT with fast transfer of associated running Unit- 2 RATs available. 1 Unit start-up on RATRAT 1A available. 1 Unit fast transfer to RAT- RAT 1A available. 1 Unit start-up with fast transfer of associated running Unit-RAT 1A available. 2 Units fast transfer- 2 RATs available.

Operating Scenarios

36

8.15

VB

50

8.15

54.3

8.15

42.3 55.1

16.3 16.3

6.9kV Bus

480V Bus

Notes

78.5

16.3

16.2

43.75

VA

Start of MDBFP Start of FD Fan Start of MDBFP

89.0 % 92.0 % 85.5 % 86.3 %

92.0 % 92.0 % 89.6 % 89.4 %

88.3 % 84.8 % -

Start of FD Fan

(a) 15% Margin on all Motors. (b) 650% FLC start current of all motors except FD Fan. (c) 610% FLC start current of FD Fan (d) ANSI 500MVA Class, max Switchgear rating 8.25kV, 63KA.

The results of these studies indicate that the 6.9kV system as specified has limitations due to the potentially connected load on reserve auxiliary buses far exceeding its capabilities. The proposed RAT of size 27.5 + 27.5/32.25 + 32.25 OA/FA will also be overloaded in the same manner as the RAT buses in all the above operating scenarios.

8. Options Considered To Contain RAT Bus Overloading

Several innovative options can be investigated to bring the loadings on the RAT buses to within the switchgear ratings. These options are briefly discussed here:

The results presented in Table 8 are the best amongst the cases so far considered. However, 63KA breakers are available only from one manufacturer and have substantially high cost as compared to 40KA and 50 KA circuit breakers. However, this option merits consideration and can prove to be effective under certain circumstances.

VB

8.1. Using 6.9kv switchgear without de-rating

The full capacity breaker with ANSI rating of 3000A at 6.9kV allows accommodating a load of 36MVA per reserve auxiliary bus. This option can be useful in certain cases but is ineffective for the present study

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Presented in AUPEC 2007, Perth, Western Australia, 9-12 December, 2007

8.2. Load Management

A combination of administrative and engineering load management procedures involve redistribution of various loads via the use of tie-breakers and alternate feeds to the buses by the Plant Operators and automatic load shedding/load blocking based on monitoring currents on different feeders and employing complex logic. It is recognized that it is impossible to predict the loading on common reserve buses at any given moment, therefore greater reliance on operators action is prone to higher human errors. However, automatic load shedding and load blocking can prove to be useful in certain cases.

no effect in increasing the system loading capacity. 50 KA, 3500A breakers offer the ability to distribute a load of 42 MVA per winding at the worst case 380kV grid voltage conditions i.e. 90% as per system design criteria. The splitting of RAT buses and using 50KA switchgear do not offer any capacity gain at minimum grid voltage when compared to the option with 3500A breakers keeping the specified system configuration. The option of using the split bus configuration with 63KA switchgear however eliminates almost all the loading restrictions at any grid voltage. As can be seen from Figure 3, the RAT size can be increased to a minimum of 96/128 MVA for this case.
90 91 92 93 94 95 96 97 98 99 100 63KA Swgr 48KA Swgr 41KA Swgr Figure 3:Load Limitations Vs. 30 kV System Voltage 380 63 42 67.5 45 32 120 72 48 34 76.5 51 36 100 81 54 38 80 85.5 57 40 90 60 42 60 94.5 63 44 99 66 46 40 103.5 69 48 20 108 72 50
0 90 91 92 93 94 95 96 97 98 99 100 380 kV System Voltage (%)

RAT Load Limit (Single LV Winding MVA)

8.3. Using higher rating buses and RAT incoming breakers

Largest circuit breaker as per ANSI switchgear rating structure has a rated current of 3000A maximum. However, at least one manufacturer produces circuit breakers with 3500A and 4000A ratings. A 3500A circuit breaker at 6.9kV can accommodate a load of 37.6 MVA at the reserve auxiliary buses when de-rated for 50oC ambient temperature. This breaker with or without de-rating could not contain the overloading as can be seen from various expected loads on the RAT buses in Table 9. However, the option of using 4000A fan cooled breaker can be considered in certain cases.

63KA Swgr

48KA Swgr

41KA Swgr

8.5. Multiple bus configuration using 48KA breakers

The principle of splitting of RAT buses can be extended to include the 6.9kV Unit buses and the medium voltage system configuration dedicating one RAT to each pair of Units (Units 1 & 2 and Units 3 & 4). Additionally, cross-ties can be provided between reserve auxiliary buses of one RAT with the corresponding buses of second RAT. Unit loads can be distributed amongst the four (4) unit buses such that one set of FD Fan and MDBFP motors are connected to one bus and the second set to the other. The other motors can be divided equally on the remaining buses. This is the most complex system configuration so far considered requiring extensive addition of breakers, buses and non-segregated buses to accomplish required connections. The voltage regulation capability of this configuration is believed to be as good as previously considered options using 50 KA circuit breakers (See Table 7) but it has the same short circuit limitations as the other considered 50 KA, 6.9kV options.

8.4. Splitting the RAT buses

The splitting of RAT buses allows the loads to be connected to the bus sections such that the loading on each section is within the limitations of the bus/breaker. This option is indicated in Figure 2.

8.6. Application of the Generator Circuit Breaker Concept

Figure 3 shows the MVA loading limit as a function of 380kV grid voltage. The MVA value indicated corresponds to the maximum allowable RAT loading beyond which the steady state voltages at 6.9kV buses will drop below 90%. Therefore, the grid voltage imposes a practical limit on the RAT capacity utilization/ratings. It can be seen from Figure 3 that with 40KA switchgear, load flow would be restricted below the 2700A breaker ratings during conditions of low 380kV grid voltage. Therefore, the elimination of temperature derating on the 3000A, 40KA breakers has
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The generator circuit breaker concept without a reserve auxiliary transformer is believed to offer cost and technical benefits and should therefore be investigated during the initial stages of project development.

9. Conclusions
The system voltage regulation and capacity limitation issues have acquired greater significance in the design of station auxiliary supply systems of large thermal power plants. This is due to large unit and station
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Presented in AUPEC 2007, Perth, Western Australia, 9-12 December, 2007

auxiliary loads that put greater demands on the switchgear equipment. There are only a few discrete choices of equipment that are commercially available. It is therefore imperative to take into account the equipment limitations when establishing the specifications and configuration of the station auxiliary supply systems of power plants. Although a single medium voltage (6.9kV) system has been successfully applied to thermal power plants in the past, the detailed studies conducted establish conclusively that this system is judged not to have acceptable voltage regulation and system capacity to satisfy the specified design criteria in all the cases. Several innovative engineering solutions presented in this paper can eliminate the voltage regulation and system capacity constraints and can bring about substantial improvements in the design of a single medium voltage (6.9kV) system. The results are encouraging and various options presented are workable from an engineering point of view in general. However, depending upon the specific design criteria and configuration of a station auxiliary supply system the application of one or a combination of various options will need careful assessment of plant loads, cost and schedule impacts and utility operating practice.

10. Acknowledgements
The authors wish to acknowledge valuable guidance provided by Mr. Shameem Qureshi Principal Design Manager Power Systems, United Group Infrastructure St. Leonards, Australia and Mr. Syed Shahid Hussain Vice President Business Development Division National Engineering Services Pakistan (pvt.) Ltd.

REFERENCES
[1]R. J. Reiman, C.A. Hatstat Selection of 6.9kV as Voltage for East Bend Station Auxiliaries IEEE Transaction on Power Apparatus and Systems, Vol. PAS-96, No. 6, November/December, 1977 2] Ted Olsen Distribution Substation Planning - Whats Changing in Metal-clad Switchgear Electrical World, April 1998 [3] EPRI, Power Plant Electrical Reference Series Auxiliary System Planning, Vol. 3 Sep. 1987. [4] Richard H. Englemann, William H. Middendorf Handbook of Electric Motors, Marcel Dekker, Inc., NY. Oct. 1994

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